In-line metallizer assemblies and part-coating conveyor systems incorporating the same

ABSTRACT

In-line metalizer assemblies can include an external rotating actuator exchange that can be operable to exchange one or more parts between a conveyor system and a vacuum chamber, and an internal rotating actuator exchange within the vacuum chamber that can be operable to receive the one or more parts from the external rotating actuator exchange, transition the one or more parts to a sputter coater integrated with the vacuum chamber for metallizing, and return metalized one or more parts to the external rotating actuator exchange such that the external rotating actuator exchange can return the metalized one or more parts to the conveyor system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation-in-part of U.S. patentapplication Ser. No. 12/688,482 filed Jan. 15, 2010, which claimspriority to Provisional Patent Application No. 61/205,200 filed Jan. 16,2009, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present specification generally relates to metallizing parts and,more specifically, to assemblies for sputter coating plastic partsin-line with conveyor systems.

BACKGROUND

Plastic and glass parts are often painted and coated with differentmaterials to change their visual appearance. For instance, plastic partsmay first receive one or more basecoats of paint or primer. Basecoatscan fill in defects left over from manufacturing and handling as well asprovide a more durable and adhesive surface for subsequent coatings. Atopcoat may also be applied to protect the basecoat or to otherwisealter the appearance of the part. Both basecoats and topcoats can beapplied to parts as they travel about a conveyor line. It can also bedesirable to produce a reflective or metallic appearance by applying areflective metal coating. The metal coating can be applied between thebasecoat and the topcoat, on top of a basecoat without a topcoat, belowa topcoat without a basecoat, or in any other combination of basecoatsand/or topcoats. For example, a thin layer of metal can be depositedonto the surface of the part using an evaporation process such as thatavailable with a batch metallizer. However, batch metalizes and otherconventional assemblies can require the collecting and racking of largequantities of parts which can, in turn, create high cycle times for themetallizing process.

Accordingly, a need exists for alternative metallizer assemblies andconveyor systems for metallizing parts.

SUMMARY

In one embodiment, an in-line metallizer assembly includes an externalrotating actuator exchange operable to exchange one or more partsbetween a conveyor system and a vacuum chamber, and, an internalrotating actuator exchange within the vacuum chamber operable to receivethe one or more parts from the external rotating actuator exchange,transition the one or more parts to a sputter coater integrated with thevacuum chamber for metallizing, and return metalized one or more partsto the external rotating actuator exchange such that the externalrotating actuator exchange can return the metalized one or more parts tothe conveyor.

In another embodiment, an in-line metallizer assembly includes anexternal rotating actuator exchange that includes one or more actuatingarms connected to a rotating pivot, the one or more actuating arms canbe operable to extend from and retract towards the rotating pivot, andthe rotating pivot being can be operable to rotate the external rotatingactuator exchange, an internal rotating actuator exchange that includesone or more internal actuating arms connected to an internal rotatingpivot, the one or more internal actuating arms can be operable to extendfrom and retract towards the internal rotating pivot, and the internalrotating pivot can be operable to rotate the internal rotating actuatorexchange, and a vacuum chamber that includes an integrated sputtercoater and houses the internal rotating actuator exchange.

In yet another embodiment, a part-coating conveyor system includes oneor more paint stations, an in-line metallizer assembly including anexternal rotating actuator exchange and an internal rotating actuatorexchange, the internal rotating actuator exchange being housed within avacuum chamber integrated with a sputter coater, wherein the in-linemetallizer assembly can be operable to continuously metalize a pluralityof parts within the part-coating conveyor system, a track connecting thein-line metallizer assembly with the one or more paint stations, and oneor more pallets operable to advance along the track between the one ormore paint stations and the in-line metallizer assembly.

These and additional features provided by the embodiments describedherein will be more fully understood in view of the following detaileddescription, in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments set forth in the drawings are illustrative and exemplaryin nature and not intended to limit the subject matter defined by theclaims. The following detailed description of the illustrativeembodiments can be understood when read in conjunction with thefollowing drawings, where like structure is indicated with likereference numerals and in which:

FIG. 1 depicts a schematic of an in-line metallizer assembly incooperation with a conveyor system according to one or more embodimentsshown and described herein;

FIG. 2 depicts a schematic of an in-line metallizer assembly incooperation with a conveyor system according to one or more embodimentsshown and described herein;

FIG. 3 depicts a schematic of another in-line metallizer assembly incooperation with a conveyor system according to one or more embodimentsshown and described herein;

FIG. 4 depicts a schematic of yet another in-line metallizer assembly incooperation with a conveyor system according to one or more embodimentsshown and described herein; and

FIG. 5 depicts a schematic of a part-coating conveyor system with anin-line metallizer assembly;

FIG. 6 depicts a side perspective view of a sputter coater of an in-linemetallizer assembly according to one or more embodiments shown anddescribed herein;

FIG. 7 depicts a top view of a part carrier on which individual partsare arranged as positioned in a sputter coater according to one or moreembodiments shown and described herein;

FIG. 8 depicts a side sectional view of the part carrier positioned inthe sputter coater along line A-A of FIG. 7;

FIG. 9 depicts a side view of components of a sputter coater having arepositionable cathode according to one or more embodiments shown anddescribed herein; and

FIG. 10 depicts a side view of components of an in-line metallizerassembly according to one or more embodiments shown and describedherein.

DETAILED DESCRIPTION

Embodiments described herein generally relate to in-line metallizerassemblies and part-coating conveyor systems incorporating in-linemetallizer assemblies. In-line metallizer assemblies generally comprisean external rotating actuator exchange and a vacuum chamber integratedwith a sputter coater. The external rotating actuator exchange may beoperable to exchange one or more parts from an adjacent conveyor systemwith one or more parts from the vacuum chamber. The vacuum chamber mayalso comprise an internal rotating actuator exchange operable totransition one or more parts between the external rotating actuatorexchange and the sputter coater. Thus, parts traveling along theconveyor system can be removed from the conveyor system, metalized(i.e., coated with a metal film), and returned to the conveyor systemfor further processing. The external rotating actuator exchange andinternal rotating actuator exchange can act in cooperation to allow forthe metallization of parts within the sputter coater while previouslymetalized parts are simultaneously exchanged with non-metalized partsoutside of the vacuum chamber. Such cooperation may allow for thecontinuous in-line metallization of parts along a conveyor system.Part-coating conveyor systems may also incorporate an in-line metallizerassembly such that a base coat, metal coat and top coat can beindependently applied to parts using a single conveyor system, such asan asynchronous conveyor system. Various embodiments of the in-linemetallizer assemblies and part-coating conveyor systems will bedescribed in more detail herein.

Referring now to FIGS. 1 and 2, an exemplary in-line metallizer assembly10 is depicted in cooperation with a conveyor system 50 as part of anexemplary part-coating conveyor system 100. As illustrated, and as willbe discussed more fully herein, the conveyor system 50 transports partsadjacent the in-line metallizer assembly 10. Pre-metalized parts 55 aretransported towards the in-line metallizer assembly 10 while metalizedparts 56 are transported away from the in-line metallizer assembly 10.An external rotating actuator exchange 20 will extend and receive (i.e.,pick-up) pre-metalized parts 55 from the conveyor system via itsactuating arms 22,23 and external door clasp 26. The external rotatingactuator exchange 20 will then retract and rotate to transport thepre-metalized parts 55 to a vacuum chamber 30. As seen in FIG. 2, thisrotation may also allow for the external rotating actuator exchange 20to simultaneously provide (i.e., drop-off) metalized parts 56 back tothe conveyor system 50. Referring to FIG. 1, an internal rotatingactuator exchange 35 disposed within the vacuum chamber 30 may thenreceive pre-metalized parts 55′ when extended (as illustrated) withinthe vacuum chamber 30. The internal rotating actuator exchange 35 canalso retract and rotate to transition pre-metalized parts 55′ within thevacuum chamber 30 to a sputter coater 40. The sputter coater can then beactivated such that parts 57 facing the metallizer 40 can undergo themetallizing process. As illustrated in FIG. 2, once the parts 56′ facingthe sputter coater 40 are fully metalized, the internal rotatingactuator exchange 35 can retract and rotate to transition the metalizedparts 56′ back towards the external rotating actuator exchange 20. Theinternal rotating actuator exchange 35 can simultaneously transition newpre-metalized parts 55′ within the vacuum chamber 30 to the sputtercoater 40. The external rotating actuator exchange 20 may then receiveand transition the metalized parts 56 back onto the conveyor system 50to complete the metallizer cycle for a given group of parts.

The conveyor system 50 may comprise any conveyor system operable tofacilitate the movement of objects (such as pallets 52, part carriers53,54 and/or one or more parts 55,56 as will become further appreciatedherein). For example, as depicted in FIGS. 1-4, the conveyor system 50may comprise one or more conveyor belts 51 that are each operable totransport a plurality of objects simultaneously. In another embodiment,the conveyor system 50 may comprise a plurality of rollers that allowfor objects to pass over the series of rollers with reduced friction. Inyet another embodiment, the conveyor system 50 may comprise a guide pathin which objects can drive along the guide path independent of oneanother. It should be appreciated that the conveyor system 50 maycomprise any alternative system, or combinations thereof, such that itfacilitates the movement of objects. In one specific embodiment, such asthat depicted in FIGS. 1-3, the conveyor system 50 may comprise aplurality of pallets 52 operable to be transported along the conveyorbelt 51. Each pallet 52 may be operable to hold a part carrier 53,54which itself may be operable to hold one or more parts 55,56. Asillustrated, part carriers carrying metalized parts 56 are identified aselement 54. Part carriers carrying pre-metalized parts 55 are identifiedas element 53. Pallets 52 may comprise any structure operable to holdone or more part carriers 53,54 and/or one or more parts 55,56. Forexample, each pallet may comprise any type of tray, plate, bin, basket,container, or other type of receptacle.

One or more parts 55,56 may thereby be transported via each pallet 52either directly or through a part carrier 53,54. Each pre-metalized part55 may comprise any object that that can be metalized in a sputtercoater 40 of the in-line metallizer assembly 10 as will becomeappreciated herein. For example, pre-metalized parts 55 may compriseplastic parts, glass parts or any other part in which a more metallic orreflective appearance is desired. In one specific embodiment,pre-metalized parts 55 may comprise injection molded plastic parts.Pre-metalized parts 55 may independently comprise any size, shape andconfiguration that allows for them to enter the vacuum chamber 30 of thein-line metallizer assembly 10. Part carriers 53,54 may comprise anyapparatus operable to support one or more parts 55,56 throughout themetallizing process. For example, part carriers may comprise a pluralityof vertical pins in which each individual part 55,56 may be supported byan individual pin. In another embodiment, part carriers 53,54 mayalternatively or additional comprise any other support structure such assupport stands, seats, platforms or stages. In one specific embodiment,part carriers 53,54 may be operable to rotate each individual part55,56. For example where a part 55,56 on a part carrier 53,54 passes byone or more fixed spray guns (such as those that apply paint or othercoating to the part), the part carrier 53,54 may rotate the parts 55,56such that paint may be applied to all areas of the parts 55,56 by asingle gun. Such an embodiment may also allow for the metallizing of theentire part 55,56 when the part is placed in front of a sputter coater40 as will become appreciated herein. The part carriers 53,54 and theiroperation in the in-line metallizer assembly 10 will be described ingreater detail below.

Still referring to FIGS. 1 and 2, the pallets 52 holding one or morepart carriers 53,54 with one or more parts 55,56 can traverse along theconveyor belt 51 of the conveyor system 50 in a first conveyor direction59. The first conveyor direction 59 may be any direction adjacent to thein-line metallizer assembly 10. More specifically, the first conveyordirection 59 may be any direction adjacent the in-line metallizerassembly that allows for an external rotating actuator exchange 20 topick up part carriers 53,54 and/or individual parts 55,56 from theconveyor system 50. The first conveyor direction 59 may comprise alinear direction tangential to the in-line metallizer assembly 10 (suchas that depicted in FIG. 1), may comprise an arced direction that passesaround the in-line metallizer assembly 10, or may comprise any otherdirection or path that allows for the external rotating actuatorexchange 20 to pick up part carriers 53,54 and/or individual parts55,56. In one embodiment, the conveyor belt 51 may further be operableto traverse in a second conveyor direction opposite the first conveyordirection. Such an embodiment may allow pallets 52 to reverse along aconveyor system 50 to receive a metal coating.

The in-line metallizer assembly 10 may be disposed adjacent the conveyorsystem 50 and may generally comprise an external rotating actuatorexchange 20, a vacuum chamber 30 with an internal rotating actuatorexchange 35, and a sputter coater 40 integrated with the vacuum chamber30. The external rotating actuator exchange 20 may comprise anyapparatus operable to exchange one or more parts between the conveyorsystem 50 and the vacuum chamber 30. Specifically, the external rotatingactuator exchange 20 may comprise an external rotating pivot 21connected to a plurality of actuating arms 22,23,24. The rotating pivotmay comprise any device operable to rotate the external rotatingactuator exchange in an external rotating direction 29. The rotatingdirection 29 can comprise a clockwise direction, a counterclockwisedirection or a combination of both (such as where the external rotatingactuator exchange 20 first rotates in a clockwise direction beforeretracing its path in a counterclockwise direction). In one embodiment,the rotating pivot 21 may comprise a swivel or rod connected to arotational drive source. The rotational drive source may be operable toturn the rotating pivot 21 to facilitate the rotation of the externalrotating actuator exchange 20 in the external rotating direction 29. Therotational drive source may comprise any type of motor, engine,pneumatic apparatus and/or alternative source for power that is operableto rotate the external rotating actuator exchange 20 when the externalrotating actuator exchange 20 is supporting one or more part carriers53,54 and/or individual parts 55,56.

The plurality of actuating arms 22,23,24 connected to the rotating pivot21 may each comprise any device operable to extend from and retracttowards the rotating pivot 21. For example, as illustrated in FIGS. 1and 2, in one embodiment, two or more actuating arms 22,24 may connectand extend from one side of the rotating pivot 21. In such anembodiment, the two or more actuating arms 22,24 may comprise ascissor-type cooperation wherein the two or more actuating arms 22,24may extend and retract in length by collapsing and expanding in heightrespectively. In another embodiment, also as illustrated in FIGS. 1 and2, a single actuating arm 23 may connect to the rotating pivot 21. Insuch an embodiment, the single actuating arm 23 may comprise anoscillating arm that may retract within itself, or may comprise a rigidarm that is driven away from and in towards the rotating pivot 21 via aball screw. It should be appreciated that the actuating arms 22,23,24may comprise any other alternative or additional configuration operableto extend from and retract towards the rotating pivot 21. The actuatingarms 22,23,24 may be connected directly to the rotating pivot 21 or maybe indirectly connected to the rotating pivot 21 through additional,arms, levers and/or other supports. Furthermore, similar to the rotatingpivot 21, the extension and retraction of the actuating arms 22,23,24may be powered by a lateral drive source operable to extend and retractthe actuating arms 22,23,24 when the external rotating actuator exchange20 is supporting one or more part carriers 53,54 and/or individual parts55,56. The lateral drive force may further be operable to selectivelyextend or retract individual actuating arms 22,23,24. For example, wherethe actuating arm facing the vacuum 30 (actuator arm 23 in FIG. 1) isrequired to maintain its extension, the other actuating arms (actuatingarms 22,23 in FIG. 1) may nonetheless be independently extended andretracted to pick up or drop of part carriers 53,54 and/or individualparts 55,56 from the conveyor system 50. In addition, the lateral drivesource and the rotational drive source may comprise a single drivesource, or may comprise a plurality of drive sources wherein each drivesource can operate independent of the other.

Still referring to the external rotating actuator exchange 20 of thein-line metallizer assembly 10 illustrated in FIGS. 1 and 2, an externaldoor clasp may be connected to each of the one or more actuating arms22,23,24 distal the rotating pivot 21. For example, as seen in FIG. 1, afirst external door clasp 26 and a second external door clasp 27 may beconnected to the actuating arms 22,23,24 distal the rotating pivot 21.The first external door clasp 26 and second external door clasp 27 maycomprise any device operable to both releasably engage one or more partcarriers 53,54 (and/or individual parts 55,56) from the conveyor system50 as well as provide a temporary vacuum seal around the entry port 25of the vacuum chamber 30. As used herein “vacuum seal” refers to a sealthat allows for an enclosed area to maintain a pressure lower than thepressure outside of the enclosed area. In one embodiment, the firstexternal door clasp 26 and second external door clasp 27 may comprise adoor with robotic grips operable to open and close about the one or morepart carriers 53,54 and/or parts 55,56. In such an embodiment, therobotic grips may maintain sufficient pressure when closed to facilitatetransportation of the one or more part carriers 53,54 and/or parts55,56. In another embodiment, the first external door clasp 26 andsecond external door clasp 27 may comprise a flat plate (such asaluminum, iron or steel) with one or more pins or protrusions operableto engage receiving holes in the part carriers 53,54 and/or parts 55,56.In such an embodiment, the first external door clasp and second externaldoor clasp may enter the receiving holes about the part carriers 53,54and/or parts 55,56 when the actuating arms 22,23,24 are extended fromthe rotating pivot 21. Likewise, the first external door clasp andsecond external door clasp may exit the receiving holes about the partcarriers 53,54 and/or parts 55,56 when the actuating arms 22,23,24 areretracted towards the rotating pivot 21. The first external door clasp26 and the second external door clasp 27 may comprise the same type ofdevice, or may each comprise a unique type of device.

As discussed above, the first external door clasp 26 and second externaldoor clasp 27 can further be operable to provide a temporary vacuum sealaround the entry port 25 of the vacuum chamber 30 to maintain vacuumpressure as will become more appreciated herein. Specifically, both thefirst external door clasp 26 and second external door clasp 27 maycomprise sufficient size to encapsulate the entry port 25 of the vacuumchamber 30. In one embodiment, the first external door clasp 26 andsecond external door clasp 27 and/or the vacuum chamber walls mayfurther comprise a periphery sealant to assist in providing a vacuumseal between the vacuum chamber 30 and one of the external door clasps26,27. In one embodiment, the periphery sealant may comprise a rubberprotrusion such as an o-ring. In such an embodiment, the vacuum chamber30 and/or the first external door clasp 26 and second external doorclasp 27 may comprise a receiving well to receive the o-ring, or theo-ring may be directly disposed between the flat surfaces of the vacuumchamber walls 36 and one of the external door clasps 26,27.

The vacuum chamber 30 of the in-line metallizer assembly 10 may bedisposed adjacent the external rotating actuator exchange 10 and maycomprise any enclosure operable to maintain vacuum pressure and house aninternal rotating actuator exchange 35. As used herein “vacuum pressure”refers to any pressure internal an enclosure that is lower than thepressure external the enclosure. The vacuum chamber 30 can therefore,for example, comprise one or more vacuum pumps 34 connected to one ormore vacuum chamber walls 36. The vacuum pump(s) 34 may be able to pumpair out from the enclosure formed by the vacuum chamber walls 36 suchthat the enclosure possesses a vacuum pressure. The vacuum pressure maycomprise any pressure less than that outside of the vacuum chamber 30and sufficient to enable the metallizing of parts within the sputtercoater 40. For example, in one embodiment the vacuum pump(s) 34 may beable to lower the pressure in the sputter coater 40 to a pressure fromabout 5 torr to about 10 torr (i.e., about 6.7 millibar to about 13.3millibar) or to a pressure as low as about 0.008 ton (i.e., about 0.01millibar).

The internal rotating actuator exchange 35 may comprise any apparatusoperable to receive one or more parts from the external rotatingactuator exchange 20, transition the one or more parts to the sputtercoater 40 for metallizing, and transition the metalized one or moreparts back to the external rotating actuator exchange 35. The internalrotating actuator exchange 35 may comprise an overall structure similarto the external rotating actuator exchange. Specifically, the internalrotating actuator exchange may comprise an internal rotating pivot 31and internal actuating arms 32,32 connected (either directly orindirectly) to the internal rotating pivot 31. The internal rotatingpivot 31 may comprise any device operable to rotate the internalrotating actuator exchange 35 in an internal rotating direction 39. Theinternal rotating direction 39 can comprise a clockwise direction, acounterclockwise direction or a combination of both (such as where theinternal rotating actuator exchange 35 first rotates in a clockwisedirection before retracing its path in a counterclockwise direction). Inone embodiment, the internal rotating pivot 31 may comprise a swivel orrod connected to an internal rotational drive source. The internalrotational drive source may be operable to turn the internal rotatingpivot 31 to facilitate the rotation of the internal rotating actuatorexchange 35 in the internal rotating direction 39. The internalrotational drive source may comprise any type of motor, engine,pneumatic apparatus and/or alternative source for power that is operableto rotate the internal rotating actuator exchange 35 when the internalrotating actuator exchange 35 is supporting one or more part carriers53,54 and/or parts 55,56 as received from the external rotating actuatorexchange 20.

The internal actuating arms 32,33 connected to the internal rotatingpivot 31 may each comprise any device operable to extend from andretract towards the internal rotating pivot 31. As discussed above withreference to the actuating arms 22,23,24 of the external rotatingactuator exchange 20, single internal actuating arms 32,33 may connectto the internal rotating pivot 31 (as illustrated in FIG. 1) or multipleinternal actuating arms may connect to the internal rotating pivot 31.The internal actuating arms 32,33 may be connected directly to therotating pivot 31 or may be indirectly connected to the internalrotating pivot 31 through additional, arms, levers and/or othersupports. Furthermore, similar to the internal rotating pivot 31, theextension and retraction of the internal actuating arms 32,33 may bepowered by an internal lateral drive source operable to extend andretract the internal actuating arms 32,33 when the internal rotatingactuator exchange 35 is supporting one or more part carriers 53,54and/or parts 55,56 as received from the external rotating actuatorexchange 20. The internal lateral drive source and the internalrotational drive source may comprise a single drive source, or maycomprise a plurality of drive sources wherein each drive source canoperate independent of one another. The internal lateral drive sourcemay further be operable to provide enough force to the internalactuating arms to maintain vacuum pressure as will become furtherappreciated herein. Furthermore, the internal lateral drive force mayalso be operable to selectively extend or retract individual internalactuating arms 32,32 independent from one another.

Still referring to the internal rotating actuator exchange 35 in thevacuum chamber 30, an internal door clasp may be connected to each ofthe one or more internal actuating arms 32,33 distal the internalrotating pivot 31. For example, as illustrated in FIGS. 1-3, a firstinternal door clasp 37 and a second internal door clasp 38 may beconnected to the internal actuating arms 32,33 distal the internalrotating pivot 31. The first internal door clasp 37 and second internaldoor clasp 38 may comprise any device operable to both hold one or morepart carriers 53,54 (and/or individual parts 55,56) as received from theexternal rotating actuator exchange 20 as well as be sealed against thevacuum chamber 30 to maintain vacuum pressure within the vacuum chamber30 and/or the sputter coater 40. For example, in one embodiment, thefirst internal door clasp 37 and second internal door clasp 38 maycomprise box-like receptacles having one open side (i.e., the side thatfaces the entry port 25 or the sputter coater 40). In such an embodimentthe part carriers 53,54 and/or parts 55,56 may be placed in the firstinternal door clasp by the external door clasps 26,27 of the externalrotating actuator exchange 20. In another embodiment, the first internaldoor clasp 37 and second internal door clasp 38 may comprise one or morepins or protrusions operable to engage receiving holes in the partcarriers 53,54 and/or parts 55,56. In such an embodiment, the firstinternal door clasp 37 and second internal door clasp 38 may enter thereceiving holes about the part carriers 53,54 and/or parts 55,56 whenthe internal actuating arms 32,33 are extended from the internalrotating pivot 31. Likewise, the first internal door clasp 37 and secondinternal door clasp 38 may exit the receiving holes about the partcarriers 53,54 and/or parts 55,56 when the internal actuating arms 32,33are retracted towards the internal rotating pivot 31. In yet anotherembodiment, the external door clasps 26,27 may be operable to mate withthe internal door clasps 37,38 such that actuation of an external doorclasp 26,27 drives actuation of an internal door clasp 37,38 when mated.Such an embodiment may allow for controlled actuation of the internaldoor clasps 37,38 despite the vacuum pressure they experience. The firstinternal door clasp 37 and second internal door clasp 38 may comprisethe same type of device, or may each comprise a unique type of device.

As discussed above, the first internal door clasp 37 and second internaldoor clasp 38 can further be operable to be sealed against the vacuumchamber 30 to maintain vacuum pressure within the vacuum chamber 30and/or the sputter coater 40. Specifically, both the first internal doorclasp 37 and second internal door clasp 38 may comprise sufficient sizeto encapsulate the entry port of the vacuum chamber 30. When an internaldoor clasp 37,38 is pushed against the vacuum chamber wall 36 about theentry port 25, the vacuum pressure within the vacuum chamber 30 willpull on the internal door clasp if an external door clasp 26,27 is notcovering the exterior of the entry port 25. Thus, the force provided bythe internal actuating arms and the internal lateral drive source mustbe sufficient to withstand the force from the external pressure suchthat the vacuum chamber 30 can maintain vacuum pressure. In oneembodiment, the first internal door clasp 37 and second internal doorclasp 38 may further comprise a periphery sealant to assist in providinga vacuum seal between the vacuum chamber 30 and one of the internal doorclasps 37,38. In one embodiment, the periphery sealant may comprise arubber protrusion such as an o-ring. In such an embodiment, the vacuumchamber 30 may comprise a receiving well that the o-ring fits into, orthe o-ring may be disposed directly between the flat surfaces of thevacuum chamber 30 and one of the internal door clasps 37,38.

Still referring to FIGS. 1 and 2, a sputter coater 40 may further beintegrated with the vacuum chamber 30. The sputter coater 40 maycomprise any device operable for applying a metal coating to partswithin the vacuum chamber 30. For example, as illustrated in FIGS. 1-3the sputter coater 40 may comprise one or more cathodes 42 comprisingthe source material (and more specifically the metal) to be depositedonto the parts. When in operation, the sputtered metal 45 will form afilm about the parts 56 such that the parts 56 are metalized andtherefore possess a metallic or reflective finish. The sputtered metalcan comprise any material operable to be sputtered onto the surface ofthe parts such as pure metals, alloys or other materials. The sputtercoater can be completely disposed within the vacuum chamber 30, or, asillustrated in FIGS. 1-3, the sputter coater walls 41 of the sputtercoater 40 may abut against the vacuum chamber walls 36 of the vacuumchamber 30 such that a vacuum pressure is present in the sputter coater40 as maintained by the vacuum pump(s) 34. In one embodiment, thepressure in the sputter coater 40 may be greater than the pressure inthe vacuum chamber 30 such that a pressure gradient exists between thetwo causing air to flow from the sputter coater 40 to the vacuum chamber30. Such an embodiment may allow for any gas injected by (or otherwisepresent in) the sputter coater 40 to flow from the sputter coater 40 tothe vacuum chamber 30. Such gases may comprise argon or other inertgases (for example, when the sputter coater 40 injects argon during thesputtering process), water vapor, air or any other injected or residualgas. In another embodiment, a plurality of sputter coaters 40 may beintegrated with the vacuum chamber 30 such that a plurality of parts canbe metalized in different sputter coaters 40 simultaneously,sequentially or in any other order or combination.

The in-line metallizer will now be explained through an exemplary methodof operation. With reference to FIGS. 1 and 2, a plurality of parts(pre-metalized parts are identified as 55 and metalized parts areidentified as 56) may be carried by part carriers (part carrierscarrying pre-metalized parts 55 are identified as 53 and part carrierscarrying metalized parts 56 are identified as 54). Each part carrier 53is initially loaded onto its own pallet 52 and transported along theconveyor system 50 in the first conveyor direction 59. Once the pallet52 reaches the in-line metallizer assembly 10, one or more actuatingarms 22,24 of the external rotating actuator exchange 10 extend suchthat the part carrier 53 is received (e.g., picked up) from the pallet52 by the first door clasp 26. Once the part carrier 53 is secured bythe first external door clasp 26, the actuating arms 22,24 retract andthe rotating pivot 21 rotates the external rotating actuator exchange 20in the external rotating direction 29 such that the part carrier 53 heldby the first door clasp 26 now faces the entry port 25 of the vacuumchamber 30.

Within the vacuum chamber 30, the first internal door clasp 38 isalready against the vacuum chamber walls 36 so that the vacuum chamberdoes not experience an increase in pressure from the outside air. Theactuating arms 22,24 supporting the first external door clasp 26 areextended so that the first external door clasp 26 is pushed against thevacuum chamber walls 36 and the part carrier 53 is passed off to thefirst internal door clasp 37 of the internal rotating actuator exchange35. While the first external door clasp 26 remains against the vacuumchamber walls (to ensure vacuum pressure is maintained inside the vacuumchamber 30), the internal actuating arms 32,33 of the internal rotatingactuator exchange 35 retract so that the first internal door clasp 37(and second internal door clasp 38) can be rotated via the internalrotating pivot 31. Specifically, the first internal door clasp 37 isrotated such that the part carrier 53 is now facing the sputter coater40, and part carrier 54 carrying just metalized parts 56 faces the firstexternal door clasp 26 of the external rotating actuator exchange 20.The internal actuating arms 32,34 are then extended so that the partcarrier 53 with pre-metalized parts 55 is pushed towards the sputtercoater 40 for metallizing. Likewise, second internal door clasp 38 nowholding the part carrier 54 with metalized parts 56 is pushed againstthe vacuum chamber walls 36 around the entry port 25 such that it facesthe first external door clasp 26 of the external rotating actuatorexchange 20. While the parts 57 are being metalized via the sputtercoater 40, the second internal door clasp 38 remains against the vacuumchamber walls 36 while the first external door clasp 26 (of the externalrotating actuator exchange 20) receives the part carrier 54 from thesecond internal door clasp 38, retracts its actuating arms 22,23,24 withthe part carrier 54, rotates via its rotating pivot 21, extends itsactuating arms 22,23,24 and provides the now metalized parts 56 on thepart carrier 54 to a waiting pallet 52.

By possessing at least two actuating arms, each with its own externaldoor clasp, the external rotating actuator exchange 20 cansimultaneously receive one or more parts from the internal rotatingactuator exchange 35 and receive one or more parts from the conveyorsystem 50 (i.e. from a pallet 52). Likewise, the external rotatingactuator exchange 20 can also simultaneously provide one or more partsto the internal rotating actuator exchange 35 and provide one or moreparts to the conveyor system 50 (i.e., to a pallet 52).

Referring now to FIG. 3, an alternative in-line metallizer assembly 11is illustrated. Similar to FIG. 1, the in-line metallizer assembly 11 ofFIG. 2 generally comprises an external rotating actuator exchange 20, avacuum chamber 30 and a sputter coater 40. However, the in-linemetallizer assembly 11 further comprises an additional transfer exchange60 for transferring the pallets 52, part carriers 53,54 and/or parts55,56 from the conveyor system 50 to the external rotating actuatorexchange 20. More specifically, the transfer exchange 60 may comprise atransfer rotating pivot 61 and or one or more transfer actuating arms62,63. The transfer exchange 60 may thereby be configured to transportpallets 52, part carriers 53,54 and/or parts 55,56 between the conveyorand the external rotating actuator exchange. In one embodiment, thetransfer exchange 60 operates in a similar manner as the externalrotating actuator exchange (wherein the transfer actuating arms 62,63would repeatedly be retracted, rotated and extended). In anotherembodiment, the transfer exchange 60 may simply transport individualpallets 52, part carriers 53,54 and/or parts 55,56 in a linear mannerbetween the conveyor and the external rotating actuator exchange 20. Itshould be appreciated that the transfer exchange 60 may alternatively oradditionally embody any other transfer mechanism and may thereby provideadditional flexibility in the location of the remaining elements of thein-line metallizer assembly 11 with respect to the conveyor system 50.

Referring now to FIG. 4, yet another in-line metallizer assembly 12 isillustrated. Similar to FIG. 1, the in-line metallizer assembly of FIG.3 comprises a vacuum chamber 30 with an integrated sputter coater 40adjacent a conveyor 350. However, the in-line metallizer assembly 12further comprises an external rotating actuator multi-exchange 70 fortransferring multiple part carriers 53,54 and/or parts 55,56 between theconveyor 350 and the vacuum chamber 30. In such an embodiment, theconveyor 350 may be used to transfer part carriers 53,54 and/or parts55,56 as described above. However, the conveyor belt(s) 351,352 of theconveyor 350 may travel in both a first conveyor direction 353 and asecond conveyor direction 354 merged by a conveyor transition 355 (suchas a bend, corner or other mechanism for changing the direction ofpallets 52, part carriers 53,54 and/or parts 55,56). Both the firstconveyor direction 353 and the second conveyor direction 354 may passadjacent the external rotating actuator multi-exchange 70.

The external rotating actuator multi-exchange 70 may comprise anexternal rotating pivot 71 and a plurality of external actuating arms 72each having an external door clasp 76 attached thereto. The externalrotating actuator multi-exchange 70 may be operable to rotate in arotating direction 77 to transition between receiving pre-metalizedparts 55 from the conveyor 350 and providing metalized parts 56 backonto the conveyor 350. The external rotating actuator multi-exchange 70may specifically be operable to simultaneously receive a new partcarrier 53 from the conveyor 350, receive or provide a part carrier53,54 to or from the vacuum chamber 30, and provide part carriers 54 tothe conveyor 350. Such an embodiment may accommodate faster cycle timesby the sputter coater 40 by simultaneously picking up and dropping offpart carriers 53,54 on the conveyor 350 as opposed to sequentiallyproviding (i.e., dropping into the pallet 52) part carriers 54 and thenreceiving new part carriers 53.

Referring now to FIG. 5, the in-line metallizer assembly 10 (comprisingan external rotating actuator exchange 20, vacuum chamber 30 andintegrated sputter coater 40) can be utilized along a part-coatingconveyor system 1000. The part-coating conveyor system 1000 can comprisea single system operable to apply a basecoat, metalized coat and topcoatusing asynchronous pallets. Specifically, the part-coating conveyorsystem 1000 can comprise a track 500, a basecoat station 600, an in-linemetallizer assembly 10, a topcoat station 700 and one or more processstations. Process stations can comprise any other station operable toassist in the application of coatings to the surface of parts. Forexample, process stations can include a surface treatment station 550, aflash oven station 800 and/or a cure station 900. The track 500 maycomprise any type of conveyor system operable to transport a pluralityof pallets 521. For example, the track can comprise a plurality oftracks with transitions and guides there between, a path for motorizedpallets to travel across, or any alternative system. In one embodiment,such as that illustrated in FIG. 5, the track 500 may specificallycomprise a main track 510 and a supplemental track 511. The supplementaltrack 511 may combine with the main track 510 to allow for two possiblepaths to arrive at the same destination. By providing two differentpaths, pallets may be directed down particular path based on thestations the pallet has already visited. In another embodiment, thetrack 500 may comprise a single continuous track operable to transitionpallets sequentially from station to station. It should be appreciatedthat any other configuration may be employed to allow pallets to travelbetween stations.

The surface treatment station 550 may comprise any station to prepare ortreat the surface of a part before, between or after undergoing coatingand/or metallizing applications. For example, in one embodiment, thesurface treatment station 550 may comprise a blow off station operableto blow off unwanted debris, excess paint, or any other material thatmay inadvertently be present. In another embodiment, the surfacetreatment station 550 may additional or alternatively comprise amechanical brush or plasma applier. The basecoat station 600 and topcoatstation 700 may comprise any stations operable to apply a basecoat and atopcoat of paint to a plurality of parts. As described above, thebasecoat station 600 and topcoat station 700 can comprise one or morespray guns that are either fixed or moveable. The one or more spray gunsmay thereby apply paint to the surface of the parts as the parts travelthrough the basecoat station 600 and/or the topcoat station 700. Thebasecoat station 600 and the topcoat station 700 may comprise distinctstations, or, in the alternative, may comprise a single station operableto apply a basecoat and a topcoat independent of the other. The flashoven station 800 may comprise any station operable to help removesolvent from a recently applied paint (e.g., the basecoat or thetopcoat). In one embodiment, the flash oven station 800 may comprise aninfrared oven. In another embodiment, the flash oven station 800 maycomprise a convective oven. It should be appreciated that the flash ovenstation 800 may comprise any other type of oven either alternatively oradditionally such that it is operable to remove solvent from parts.Finally, the cure station 900 may comprise any station operable to curepaint recently applied to a part (e.g., the basecoat or the topcoat).The cure station 900 may comprise any combination of length andtemperature to enable the curing of UV paints. In one embodiment, thecure station may comprise a UV cure station where UV light is applied toassist in the curing of the paint. It should further be appreciated thatany other types of cure stations may be employed, either alternativelyor additionally, to help cure the paint applied to a part.

In one embodiment, the part-coating system 1000 can further comprise apart molder operable to create the original parts. The part molder cancomprise any machine operable to produce plastic parts, such as, forexample, an injection molding machine. In such an embodiment, the partmolder may be integrated with the track 500 such that parts producedfrom the part molder can directly travel along the track 500 to thebasecoat station 600, the metallizer assembly 10, the topcoat stationand/or any process station. Such an embodiment may allow for parts toforgo receiving basecoats by reducing the waiting time before beingmetalized or receiving a topcoat (and thereby reducing the chances thesurface of the parts are scratched or otherwise damaged).

Still referring to FIG. 5, the track 500 can further comprise pallets521 staged in asynchronous groups. Asynchronous groups 520 can comprisea single pallet 521 (such that each group is just a single pallet 521),a set number of pallets 521 (such that each asynchronous group 520comprises the same set number of pallets 521), or any independent numberof pallets 521 (such that each asynchronous group 520 can comprise anynumber of pallets 521 independent from one another). Asynchronous groupsare groups that can travel along the track 500 independent of oneanother. For example, as opposed to a “chain-on-edge conveyor” (i.e., aconveyor in which all parts are transported by a continuous chain suchthat each part starts and stops in synch), asynchronous pallets on thetrack 500 can start and stop independent of one another. In such anembodiment, the movement and direction of each asynchronous group 520 ofpallets 521 can be achieved through the use of RFID tags, scanners,flags, electrical signals, machine logic part mapping or any otheralternative method for tracking the status of parts to direct them tosubsequent stations.

In operation, one or more parts are loaded into pallets 521 on the track500 via one or more loaders 540. The one or more loaders 540 cancomprise any combination of manual or automatic loaders operable to loadand unload parts, part carriers and/or pallets onto the track 500. Thepallets 521 are arranged in asynchronous groups 520 where each pallet521 in the asynchronous group 520 holds parts that are at a common stage(such as no paint, base coat only, base coat and metalized coat or allcoats). An asynchronous group 520 of pallets 521 with newly molded parts(i.e., no paint coatings) may first be directed to the surface treatmentstation 550 to blow off unwanted debris left over from initialmanufacturing, or otherwise be treated to improve adhesion such asthrough the use of flames, corona or other type of plasma. Theasynchronous group 520 of pallets 521 is then directed through thebasecoat station 600 where an initial base coat (e.g., a primer coat) isapplied. The base coat can help fill in surface defects left over frommanufacturing as well as provide durability and color. After theasynchronous group 520 of pallets 521 passes through the basecoatstation 600, it is directed to the flash oven station 800 and/or curestation 900 so that the basecoat can set. It should be noted that wherethe basecoat station 600 and topcoat station 700 are two separatestations in the same track line (as illustrated in FIG. 5), theasynchronous group 520 of pallets 521 could pass through the topcoatstation without actually stopping to receive the topcoat application.Depending on the desired treatment, the asynchronous group 520 ofpallets 521 can return to the basecoat station 600 to receive additionalbasecoats such that the parts are coated with a plurality of basecoats(such as a primer coat and a first coat of base paint). In thealternative, asynchronous group 520 of pallets 521 may independentlybypass the basecoat station 600 such as where parts are freshlymanufactured and have not acquired surface abrasions, scratches or otherdefects.

After completion and setting of the basecoat, the asynchronous group 520of pallets 521 would then be directed to the in-line metallizer assembly10. The external rotating actuator exchange 20 of the in-line metallizerassembly 10 may thereby continuously pickup the parts from the pallets521 (either individually or via part carriers) for metallizing whilealso returning the metalized parts to pallets 521. The in-linemetallizer assembly 10 can thereby alleviate the need to collect andremove large batches of parts to be metalized when employing a batchmetallizer. Once the parts of the asynchronous group 520 of pallets 521are all metalized, the asynchronous group 520 of pallets 521 is directedto the topcoat station 700 (potentially via passing through the basecoatstation 600 without actually receiving a basecoat). After receiving atopcoat from the topcoat station 700, the asynchronous group 520 ofpallets 521 is directed to the flash oven station 800 and cure station900. Finally, the completed products in the asynchronous group 520 ofpallets 521 may be removed from the track 500 by the manual or automaticloaders 540.

Where a particular machine or part breaks down thereby stopping part ofthe part-coating conveyor system 1000, asynchronous groups 520 ofpallets 521 with partially completed parts may continue on whereoperable. For example, if the basecoat station 600 breaks down, newasynchronous groups 520 of pallets 521 cannot receive a basecoat ofpaint. However, asynchronous groups 520 of pallets 521 that have alreadypassed through the basecoat station 600 can nonetheless continue throughthe application cycle since the entire track 500 is not stopped. Unlikechain-on-edge configurations, the asynchronous groups 520 help ensureparts that have received one or more coats of paint can be finalizedwithout excessive downtime, which in turn can decrease the number ofparts lost to quality control.

Referring now to FIG. 6, a portion of the in-line metallizer assembly 10is depicted. In this embodiment, the sputter coater 40 of the in-linemetallizer assembly 10 is depicted with certain components, includingthe vacuum chamber 30 and the internal rotating pivot 31, removed forclarity. As depicted in FIG. 6, individual parts 57 are positioned onthe plurality of rotatable pin fixtures 58 of the part carriers 54. Asdescribed hereinabove, the part carriers 54 are introduced to thesputter coater 40 as to position the individual parts 57 proximate tothe cathodes 42 to complete the metallization process on the individualparts 57.

The in-line metallizer 10 also includes a rotation mechanism 620, whichis shown in greater detail in FIGS. 7 and 8. Referring to FIG. 7, therotation mechanism 620 includes a continuous drive element 622 that isarranged around a first drive gear 624 and a second drive gear 626. Thecontinuous drive element 622 may take a variety of forms including, forexample and without limitation, a drive chain or a belt. The first drivegear 624 and the second drive gear 626 may be spaced apart from oneanother as to adjust the tension on the continuous drive element 622.Alternatively, or in addition, the rotation mechanism 620 may include atensioning gear (not shown) that maintains tension on the continuousdrive element 622.

Referring now to FIG. 8, the in-line metallizer 10 also includes a driveshaft 628 that extends through the sputter coater wall 41 of the sputtercoater 40. The drive shaft 628 is coupled to one of the first drive gear624 or the second drive gear 626 of the rotation mechanism 620. Rotationof the drive shaft 628, therefore, directly controls rotation of one ofthe first drive gear 624 or the second drive gear 626 and controlstranslation of the continuous drive element 622 around the first andsecond drive gears 624, 626. The in-line metallizer 10 also includes arotary feed-through 630 which is coupled to the sputter coater wall 41of the sputter coater 40. The rotary feed-through 630 allows the driveshaft 628 to pass through the sputter coater wall 41, while maintaininga fluid-tight seal between the sputter coater wall 41 and the driveshaft 628 such that at a vacuum can be pulled inside the sputter coater40.

As further depicted in FIG. 8, the in-line metallizer 10 furtherincludes a rotation drive 640 positioned outside of the sputter coater40 and coupled to the drive shaft 628. The rotation drive 640 may take avariety of forms including, for example and without limitation, anelectric motor or a servo motor. As depicted in FIG. 8, the rotationdrive 640 and the drive shaft 628 are separated by a flexible coupling632, which are conventionally known. The flexible coupling 632 allowsfor misalignment between the drive shaft 628 and the rotation drive 640while minimizing the introduction of any misalignment force into thedrive shaft 628. Reducing misalignment force into the drive shaft 628may reduce the likelihood of loss of a fluid tight seal between thedrive shaft 628 and the sputter coater walls 41 at the rotaryfeed-through 630. The in-line metallizer 10 may also incorporatetransmission (not shown) arranged between the rotation drive 640 and thedrive shaft 628 to increase or decrease the rate of rotation of thedrive shaft 628 as compared to the rotation drive 640. In someembodiments, a transmission may be incorporated integrally into therotation drive 640.

The in-line metallizer 10 also includes an electronic controller 650communicatively coupled to rotation drive 640. The electronic controller650 includes a processor 652 and a memory 654 electrically coupled tothe processor 652. A computer readable instruction set is stored in thememory 654 and is executed by the processor 652 to provide the rotationdrive with instructions to rotate or to hold position. The electroniccontroller 650 may include a graphical display 656 that displaysoperating parameters of the rotation mechanism 620 and/or the rotationdrive 640 to a user. The graphical display 656 may allow a user to makeinputs to the electronic controller 650 to modify operation of therotation drive, for example to change the rate of rotation of therotation drive 640.

Still referring to FIG. 8, the part carriers 54 are shown in greaterdetail. In the embodiment depicted in FIG. 8, the part carrier 54includes a support frame 542 and a lifting body 544. The support frame542 includes a plurality of rotatable pin fixtures 58 which arepositioned spaced apart from one another along the support frame 542.The rotatable pin fixtures 58 include a support shaft 549 that extendsthrough openings in the support frame 542, and a fixture gear 548rotatationally coupled to the support shaft 549. The fixture gear 548and the support shaft 549 rotate together with respect to the supportframe 542 of the part carrier 54. In some embodiments, the part carrier54 may include a plurality of bearing elements (not shown) whichposition the support shafts 549 relative to the support frame 542 andminimize friction between the support shafts 549 and the support frame542.

In the embodiment depicted in FIG. 8, the support frame 542 of the partcarrier 54 is spaced apart from the lifting body 544 with a biasingelement 546. In the embodiment depicted in FIG. 8, the biasing element546 includes a pin 545 that is adapted to slide relative to at least oneof the support frame 542 or the lifting body 544, and a spring 547. Thespring 547 applies a force to both the support frame 542 and the liftingbody 544 in an orientation that tends to separate the support frame 542from the lifting body 544.

As discussed hereinabove, individual parts 57 are loaded onto the partcarriers 54 and are introduced into the sputter coater 40 for completionof a metallizing operation. In regard to the embodiments of the in-linemetallizer 10 depicted in FIG. 8, one of the internal door clasps 37, 38(see FIG. 1) interfaces with the lifting body 544 of the part carrier 54and positions the part carrier 54 within the sputter coater 40. As thepart carrier 54 is rotated into position in the sputter coater 40 by therotating actuator exchange 35 (see FIG. 1), the fixture gear 548 of therotatable pin fixture 58 interfaces with the continuous drive element622 of the rotation mechanism 620. The gear profiles of the fixture gear548 interface with the continuous drive element 622 such that thecontinuous drive element 622 controls rotation of the fixture gear 548,and therefore the rotatable pin fixture 58 and the individual part 57positioned on the rotatable pin fixture 58. As the part carrier 54 ismoved into position in the sputter coater 40, the continuous driveelement 622 may apply a force to the fixture gears 548. This force maytend to maintain engagement of the fixture gears 548 with the continuousdrive element 622. Further, because of tolerance variations between thepart carriers 54 and variation in the relative positioning of thefixture gears 548 and the continuous drive element 622, some variationin the positioning of the part carrier 54 and the continuous driveelement 622 may be expected. To accommodate this variation inpositioning between the part carrier 54 and the continuous drive element622, the support frame 542 of the part carrier 54 may compress thebiasing element 546 and be repositioned towards the lifting body 544. Byallowing the support frame 542 to be repositioned with respect to thelifting body 544, variation in spacing between the fixture gears 548 andthe continuous drive element 622 can be accommodated by the part carrier54.

Referring again to FIG. 6, the individual parts 57 are introduced to thesputter coater 40 and positioned proximate to the cathodes 42 forcompletion of the metallizing operation. In some embodiments of thein-line metallizer assembly 10, the rotation mechanism 620 causes therotatable pin fixtures 58, and therefore the individual parts 57, torotate continuously during the metallizing operation such that thefixed-position cathodes 42 metalize all of the surfaces of theindividual parts 57 having line-of-sight access to the cathodes 42. Byrotating the individual parts 57 during the metallizing operation, acontinuous metalized layer can be applied to the individual parts 57. Inother embodiments of the in-line metallizer assembly 10, the rotationmechanism 620 limits rotation of the rotatable pin fixtures 58, andtherefore the individual parts 57, during the metallizing operation suchthat only those limited surfaces of the individual parts 57 with line-ofsight-access to the cathodes 42 are metalized. Such embodiments of thein-line metallizer assembly 10 may incorporate a servo motor or astepper motor as the rotation device 640 such that rotation of therotatable pin fixtures 58 can be minimized and/or eliminated.Orientation of the individual parts 57 relative to the cathodes 42 allowfor complete or partial metallization of the individual parts 57, asdictated by a particular design.

As discussed hereinabove, embodiments of the in-line metallizer assembly10 include an electronic controller 650 that control operation of therotation device 640 such that the rotation device 640, and therefore thecontinuous drive element 620, the rotatable pin fixtures 58, and theindividual parts 57 rotate at the desired rate of rotation and/or ispositioned at the desired angular orientation relative to the cathodes42. The electronic controller 650 may execute the computer readableinstruction that commands the desired response from the rotation device640. Alternatively or in addition, a user may intervene as to modifyoperation of the rotation device 640 such that the rotation device 640conforms to the desired operation for a particular metallizingoperation. Further, properties of the metallization operation includingprocess gas type, process gas flow rate, chamber vacuum pressure,individual part orientation, individual part position, and individualpart rate of rotation may be controlled by the electronic controller 650to allow for repeatable processing across a plurality of individualparts 57 and part setups. As such, consistent part manufacture may beachieved across separate processing batches.

Referring now to FIG. 9, components of another embodiment of the in-linemetallizer assembly 10 are depicted. In this embodiment, componentspositioned within the sputter coater 40 are depicted. In thisembodiment, the cathode 42 that metalizes the individual components 57is repositionable in a vertical direction 710 and a horizontal direction712, and is tiltable in a vertical orientation 714 as well as ahorizontal orientation 716. In the embodiment depicted in FIG. 9, thecathode 42 is coupled to a cathode frame 720 positioned within thesputter coater 40. The cathode frame 720 depicted in FIG. 9 allows thecathode 42 to be adjusted in the directions of freedom of movement(i.e., the vertical direction 710, the horizontal direction 712, thevertical orientation 714, and the horizontal orientation 716)independently of one another, such that the cathode 42 can be positionedto provide the desired line-of-sight access to the individual parts 57.In the embodiment depicted in FIG. 9, the in-line metallizer assembly 10further includes cathode drive mechanisms 722 that modifies the positionof the cathode 42 along the cathode frame 720 or the orientation of thecathode 42 relative to the cathode frame 720.

In some embodiments of the in-line metallizer assembly 10, the cathodedrive mechanisms 722 may be linear-acting servo motors that directlytranslate the cathode 42 in the vertical direction 710 or the horizontaldirection 712. Similarly, the cathode drive mechanisms 722 may berotary-acting servo motors that tilt the cathode 42 in the verticalorientation 714 or the horizontal orientation 716. Alternatively or inaddition, the cathode drive mechanism 722 may include a remote trackingapparatus (not shown) similar to rotation mechanism 620 described aboveand depicted in FIGS. 6-8. Incorporation of a remote tracking apparatuswith the cathode frame 720 may allow for the cathode drive mechanisms722 to be positioned remotely from the sputter coater 40.

Similar to the rotation device 640 described hereinabove, the cathodedrive mechanisms 722 may be coupled to the electronic controller 650.The electronic controller 650 executes the computer readable instructionset and selectively commands the cathode drive mechanisms 722 to tiltand/or translate the cathode in at least one directions of freedom ofmovement (i.e., the vertical direction 710, the horizontal direction712, the vertical orientation 714, and the horizontal orientation 716)relative to the cathode frame 720 as to control the angular orientationand/or positional location of the cathode 42 within the sputter coater40.

In one embodiment, the cathode frame 720 may be oriented in a planarorientation or a non-planar orientation, where the cathode 42 followsalong the cathode frame 720. In one embodiment, the cathode frame 720may be arched such that the cathode 42 moves in both the verticaldirection 710 and the horizontal direction 712 when the cathode 42 istranslated along the cathode frame 720.

While the embodiment of the in-line metallizer assembly 10 depicted inFIG. 9 includes a single cathode 42, it should be understood that thein-line metallizer assembly 10 may include a plurality of cathodes 42arranged within the sputter coater 40, where each cathode 42 may beoriented to deliver sputter coating to the surfaces of the part.

Referring now to FIG. 10, portions of another embodiment of the in-linemetallizer assembly 10 is depicted. In this embodiment, the in-linemetallizer assembly 10 includes a buffer gas system 740 that ispositioned proximate to the external rotating actuator exchange 20 andthe vacuum chamber 30. The buffer gas system 740 includes an enclosure742 that is positioned to at least partially enclose the vacuum chamber30 and the external rotating actuator exchange 20. The endwall 744 ofthe enclosure 742 may be positioned such that the first and secondexternal door clasps 26,27 selectively form a temporary seal with theendwall 744 of the enclosure 742 when the respective first or secondexternal door clasp 26,27 is positioned in an extended position. Atleast a portion of the external rotating actuator exchange 20 may extendthrough an opening in the enclosure 742, thereby allowing the externalrotating actuator exchange 20 to exchange parts between the conveyorsystem 50 and the internal rotating actuator exchange 35.

The buffer gas system 740 also includes a pressurized gas deliverysystem 750 that is plumbed to the enclosure 742 and provides theenclosure 742 with gas at a pressure greater than the ambient pressureoutside of the enclosure 742. As used herein, the gas introduced to theenclosure 742 may be any gas including, for example and withoutlimitation, air, oxygen, nitrogen, helium, argon, neon, and the like. Inone embodiment, the pressurized gas delivery system 750 includes adesiccation device 752 that reduces the humidity of gas passing throughthe pressurized gas delivery system 750 into the enclosure 742. In someembodiments, the pressurized gas delivery system 750 may further includea temperature conditioning device 754 that adjusts the temperature ofthe gas directed into the enclosure 742 and a filtration device 756 thatcaptures particulates from the gas before the gas is directed into theenclosure 742. The buffer gas system 740 may also include a gas knife746 positioned within the enclosure 742 and supplied with pressurizedbuffer gas from the gas delivery system 750. The gas knife 746 directs acurtain of pressurized buffer gas in a generally planar orientation.

Pressurized buffer gas is delivered to the enclosure 742 such thatbuffer gas generally fills the enclosure 742. Because the pressurizedbuffer gas is maintained at a pressure above ambient within theenclosure 742, the buffer gas flows out into the surrounding environmentand limits ingestion of untreated environmental air into the enclosure742. Introduction of contaminants such as dust and moisture to thevacuum chamber 30 and the sputter coater 40 may negatively impact themetallizing process on pre-metalized parts 55 by the sputter coater 40.Reducing ingestion of untreated environmental air that carries suchcontaminants into the enclosure 742, reduced the likelihood of ingestionof untreated environmental air into the vacuum chamber 30 and thesputter coater 40 as the part carriers 54 are moved for sputter coatingthe pre-metalized parts 55, as discussed hereinabove. In particular,pressurized buffer gas may be introduced to the enclosure 742 at a rategreater than gas enters the vacuum chamber 30 during the exchange ofpart holders 54 and parts 55 by the external rotating actuator exchange20.

Because of the short cycle time in which the parts 55 are metalized, thevacuum pumps 34 that evacuate gas from the vacuum chamber 30 and thesputter coater 40 may have difficulty in removing gas that is introducedto the vacuum chamber 30 and the sputter coater 40 during the partcarrier 54 exchanges within one cycle of operation of the sputter coater40. Further, any condensation that is introduced to the vacuum chamber30 and the sputter coater 40 may tend to collect along surfaces of thevacuum chamber 30 and the sputter coater 40, increasing the difficultyof removing the moisture from the vacuum chamber 30 and the sputtercoater 40. Therefore, by flooding the enclosure 742 with pressurizedbuffer gas from the pressurized gas delivery system 750, ingestion ofcontaminants into the enclosure 742, and therefore the vacuum chamber 30and the sputter coater 40, may be reduced. Accordingly, in-linemetallizer assembly 10 that incorporate a buffer gas system 740 mayincrease the yield of metalized parts 56 produced.

As depicted in FIG. 10, the gas knife 746 is positioned within theenclosure 742 proximate to the opening through which the externalrotating actuator exchange 20 exchanges parts along the conveyor system50. As discussed hereinabove, the gas knife 746 is provided withpressurized buffer gas that is ejected from the gas knife 746 in agenerally planar orientation, such that the gas knife 746 forms a “gascurtain.” The gas knife 746 may include a flow tube that is perforatedwith a plurality of holes or slots that direct passage of pressurizedbuffer gas. By positioning the gas knife 746 such that the pre-metalizedparts 55 pass through the gas curtain as the part carriers 54 areexchanged, the gas knife 746 may direct pressurized buffer gas onto thepre-metalized parts 55 as to dislodge any contaminants and/or dry anymoisture from the pre-metalized parts 55 before the pre-metalized parts55 are exchanged into the vacuum chamber 30 and the sputter coater 40.Thus, the gas knife 746 further reduces the likelihood of ingestion ofcontaminants into the vacuum chamber 30.

It should now be appreciated that in-line metallizer assemblies maycontinuously metalize parts off of a conveyor belt without the need forbatch loading/unloading. In-line metallizer can continuously pick upparts from a conveyor belt and swap them with recently metalized parts.The newly picked-up parts may be transferred to a vacuum chamber wherethey can be metalized and returned. While parts are being metalizedinside the vacuum chamber, a new set of pre-metalized parts is picked upand exchanged with the most recently metalized parts. This in-linemetallizer assembly may further be combined with an asynchronouspart-coating conveyor system to efficiently apply a basecoat, metalizedcoat and topcoat to a part. The asynchronous grouping of pallets canhelp ensure partially completed pallets receive their next coats beforean undesirable amount of time passes.

It is noted that the terms “substantially” and “about” may be utilizedherein to represent the inherent degree of uncertainty that may beattributed to any quantitative comparison, value, measurement, or otherrepresentation. These terms are also utilized herein to represent thedegree by which a quantitative representation may vary from a statedreference without resulting in a change in the basic function of thesubject matter at issue.

While particular embodiments have been illustrated and described herein,it should be understood that various other changes and modifications maybe made without departing from the spirit and scope of the claimedsubject matter. Moreover, although various aspects of the claimedsubject matter have been described herein, such aspects need not beutilized in combination. It is therefore intended that the appendedclaims cover all such changes and modifications that are within thescope of the claimed subject matter.

What is claimed is:
 1. An in-line metallizer assembly for sputtercoating pre-metalized parts, the in-line metallizer assembly comprising:a vacuum chamber; a sputter coater in communication with the vacuumchamber and comprising a cathode and a sputter coater wall; an internalrotating actuator exchange positioned within the vacuum chamber forexchanging pre-metalized parts into the sputter coater and metalizedparts out of the sputter coater, the internal rotating actuator exchangecomprising an internal rotating pivot, internal actuating arms that arecoupled to the internal rotating pivot and are adapted to extend andretract from the internal rotating pivot, and a first internal doorclasp and a second internal door clasp that are each coupled to one ofthe internal actuating arms; a part carrier comprising at least onerotatable pin fixture, a lifting body, a support frame that is spacedapart from the lifting body, and a biasing element comprising a pin thatslides relative to at least one of the lifting body or the support frameof the part carrier and spring that applies a force to the lifting bodyand the support frame, wherein the biasing element may be compressedsuch that a relative position between the lifting body and the supportframe is repositionable along the pin, the part carrier adapted to bemoved into and out of the sputter coater by the internal rotatingactuator exchange; a rotation mechanism positioned within the sputtercoater, the rotation mechanism selectively coupled to the at least onerotatable pin fixture, wherein the biasing element maintains contactbetween the at least one rotatable pin fixture and the rotationmechanism; and a drive shaft extending into the sputter coater throughthe sputter coater wall and coupled to the rotation mechanism forcontrolling rotation of the at least one rotatable pin fixture.
 2. Thein-line metallizer assembly of claim 1, further comprising a pluralityof rotatable pin fixtures, wherein each rotatable pin fixtures isselectively coupled to the rotation mechanism.
 3. The in-line metallizerassembly of claim 1, wherein: the rotation mechanism comprises acontinuous drive element arranged around a first drive gear and a seconddrive gear, the at least one rotatable pin fixture comprises a fixturegear rotationally coupled to a support shaft, the fixture gear and thesupport shaft rotate together with respect to the part carrier; and thepart carrier is selectively positioned within the sputter coater suchthat the fixture gear meshes with the continuous drive element of therotation mechanism.
 4. The in-line metallizer assembly of claim 1,further comprising a rotation drive that is positioned outside of thevacuum chamber and is coupled to the drive shaft.
 5. The in-linemetallizer assembly of claim 4, wherein the rotation drive is a servomotor or an electric motor.
 6. The in-line metallizer assembly of claim4, further comprising an electronic controller communicatively coupledto the rotation drive, the electronic controller comprising a processorand a memory electrically coupled to the processor, the memory storing acomputer readable instruction set that, when executed by the processor,selectively commands rotation and/or indexed positioning of the rotationdrive thereby controlling an angular orientation of the at least onerotatable pin fixture.
 7. An in-line metallizer assembly for sputtercoating pre-metalized parts, the in-line metallizer assembly comprising:a vacuum chamber; a sputter coater in communication with the vacuumchamber and comprising a cathode frame positioned within a vacuumchamber and a cathode coupled to the cathode frame; an internal rotatingactuator exchange positioned within the vacuum chamber for exchangingpre-metalized parts into the sputter coater and metalized parts out ofthe sputter coater, the internal rotating actuator exchange comprisingan internal rotating pivot, internal actuating arms that are coupled tothe internal rotating pivot and are adapted to extend and retract fromthe internal rotating pivot, and a first internal door clasp and asecond internal door clasp that are each coupled to one of the internalactuating arms; a part carrier comprising at least one rotatable pinfixture, a lifting body, a support frame that is spaced apart from thelifting body, and a biasing element comprising a pin that slidesrelative to at least one of the lifting body or the support frame of thepart carrier and spring that applies a force to the lifting body and thesupport frame, wherein the biasing element may be compressed such that arelative position between the lifting body and the support frame isrepositionable along the pin, the part carrier adapted to be moved into,maintained in position within, and out of the sputter coater by theinternal rotating actuator exchange; and a rotation mechanism positionedwithin the sputter coater, the rotation mechanism selectively coupled tothe at least one rotatable pin fixture, wherein the biasing elementmaintains contact between the at least one rotatable pin fixture and therotation mechanism; wherein the cathode has at least one direction offreedom of movement as to be selectively positioned within the sputtercoater.
 8. The in-line metallizer assembly of claim 7, wherein the atleast one direction of freedom of movement allows the cathode to betilted in a vertical orientation.
 9. The in-line metallizer assembly ofclaim 7, wherein the at least one direction of freedom of movementallows the cathode to be tilted in a horizontal orientation.
 10. Thein-line metallizer assembly of claim 7, wherein the at least onedirection of freedom of movement allows the cathode to be translated ina vertical direction.
 11. The in-line metallizer assembly of claim 7,wherein the at least one direction of freedom of movement allows thecathode to be translated in a horizontal direction.
 12. The in-linemetallizer assembly of claim 7, further comprising a cathode drivemechanism coupled to the cathode and the cathode frame, the cathodedrive mechanism modifies the position and/or orientation of the cathoderelative to the cathode frame in the at least one direction of freedomof movement.
 13. The in-line metallizer assembly of claim 12, whereinthe cathode drive mechanism comprises at least one linear servo motor.14. The in-line metallizer assembly of claim 12, wherein the cathodedrive mechanism comprises at least one rotary servo motor.
 15. Thein-line metallizer assembly of claim 12, further comprising anelectronic controller communicatively coupled to the cathode drivemechanism, the electronic controller comprising a processor and a memoryelectrically coupled to the processor, the memory storing a computerreadable instruction set that, when executed by the processor,selectively commands the cathode drive mechanism to tilt and/ortranslate the cathode in the at least one direction of freedom ofmovement relative to the cathode frame as to control an angularorientation and/or positional orientation of the cathode within thesputter coater.
 16. The in-line metallizer assembly of claim 1, furthercomprising an external rotating actuator exchange positioned outside ofthe vacuum chamber and adapted to exchange part carriers into and out ofthe vacuum chamber, the external rotating actuator exchange comprisingan external rotating pivot, external actuating arms that are coupled tothe external rotating pivot and are adapted to extend and retract fromthe external rotating pivot, and a first external door clasp and asecond external door clasp that are each coupled to one of the externalactuating arms.
 17. The in-line metallizer assembly of claim 1, furthercomprising a rotary feed-through that is coupled to the sputter coaterwall of the sputter coater, the rotary feed-through forming afluid-tight seal between the sputter coater wall and the drive shaft.